Modular Structures

ABSTRACT

The present invention relates generally to a building or shelter system  10  comprising a series of structures or modular frames  12 A to  12 F being arranged generally parallel to and laterally spaced from one another and interconnected with roof sheeting  14.  The modular frames such as  12 A are each in their erected condition in the form of a roof truss each including a plurality of constructional modules or truss modules or panels such as  16 A and  16 B. The truss modules or panels such as  16 A are each shaped in the form of a trapezium including upper and lower substantially parallel chord members  18  and  20,  respectively, which are interconnected at opposite ends with web members  22  and  24.  the structure or module frame  12 A includes conditioning elements arranged to cooperate with the constructional modules or truss panels such as  16 A and  16 B to form the module frame  12 A. The conditioning elements include tendons which locate within the hollow section of the upper and/or lower chord member  18  or  20  of adjacent and abutting truss panels such as  16 A and  16 B. The conditioning elements or lower tendon such as  28  is deployed or stressed/tensioned to facilitate cooperative movement of the truss panels  16 A and  16 B and as such erection of the modular frame  12 A.

FIELD OF THE INVENTION

The present invention relates broadly to a constructional module and astructure including a plurality of constructional modules. The inventionfurther relates generally to a method of construction and relatesparticularly, though not exclusively, to a method of buildingconstruction including roof truss construction.

BACKGROUND OF THE INVENTION

Buildings that can be deployed quickly and efficiently are commonlyrequired for example in military use. Such temporary structures aretypically used in establishing a base camp and include buildings foraccommodation, workshops, control facilities, amenities and as equipmentstores. Further, some buildings are required to have large clear spansin the order of 20 m or more to house for example major equipment suchas aircraft, and vehicles. As the structures often are located in remoteareas and need to be assembled in hostile conditions, there is acontinuing need to provide such redeployable structures that can beerected and disassembled more effectively.

Improvements in material technology and construction methodology haveallowed large redeployable structures to be transported and erected.Newer technologies such as air-supported structures have evolved butrequire mechanical equipment, pumps, fuel etc to maintain and areunderstood not to be well regarded for expeditionary type roles. Forlarger structures suitable for heavy machinery, aircraft and the like,tent-like solutions do not scale particularly well.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided aconstructional module being adapted to engage one or more othercorresponding constructional modules to form a structure, said modulebeing of a predetermined configuration and adapted to cooperate with oneor more conditioning elements wherein the structure is configurabledepending on the relative positioning of the modules and/or deploymentof the conditioning elements.

According to another aspect of the invention there is provided astructure comprising:

-   -   a plurality of constructional modules being of a predetermined        configuration; and    -   one or more conditioning elements being arranged to cooperate        with the constructional modules wherein adjacent of said modules        engage one another to form the structure which is configurable        depending on the relative positioning of the modules and/or        deployment of the conditioning elements.

Preferably the constructional module is of a composite construction.More preferably the composite constructional module is fabricated from afibre composite material such as a particulate filled resin materialwith high strengths fibre reinforcement, or a polyester resin basedmaterial. Alternately the constructional module is formed from apolymeric material and may, for example, be pultruded.

Preferably the constructional module is shaped in the form of atrapezium including upper and lower substantially parallel chord membersbeing interconnected at opposite ends with respective web members. Morepreferably each of the constructional modules is of a substantiallyidentical shape. Even more preferably the chord and web members areformed as hollow section members, for example square hollow section(SHS) members. Still more preferably the trapezium-shaped constructionalmodule includes a pair of diagonal web members arranged to add rigidityto the module.

Preferably the conditioning elements are each in the form of tendonswherein deployment of said elements is effected by stressing of thetendons. More preferably the tendons are designed to locate within thehollow section of the lower and/or upper chord member, and stressing ofthe tendons involves pre-stressing or post tensioning of the tendons andthe corresponding chord member. Even more preferably the lower chordonly includes one or more of the tendons. Alternately, and to provideadditional rigidity to the structure, both the upper and the lower chordmembers include said tendons which for example suit the structure tohigher load applications such as typhoonic/cyclonic wind.

Preferably the constructional module includes interlocking means beingarranged to provide interlocking of the adjacent modules. Morepreferably the interlocking means includes an integral spigot beingadapted to engage a hole of an adjacent module, or vice versa, anddesigned to permit pivotal movement between adjacent of said modules ondeployment of the conditioning elements. Even more preferably the spigotor hole allows a hinged action between said adjacent modules. Still morepreferably the spigot and/or hole together with the surrounding portionof the constructional module is reinforced. Alternatively theinterlocking means at top chord level includes a pivotal or hingedconnector such as a clevis/pin type arrangement.

Preferably the structure also comprises packer elements being designedto locate between adjacent of the constructional modules to effectreconfiguration of the structure.

Preferably the structure is a building structure, and in particular aroof truss. More preferably each of the constructional modules is atruss module.

Preferably the roof truss is clad with elongate and transverselyoriented sheeting. More preferably the sheeting is of a channel sectionand fabricated of a rigid material including a plastic such as PVC orABS, or metallic material. Alternately the cladding is made from afabric such as canvas.

Preferably the structure is redeployable.

According to a further aspect of the invention there is provided amethod of construction, said method including the steps of:

-   -   providing a plurality of constructional modules each being of a        predetermined configuration, and one or more conditioning        elements being arranged to cooperate with said modules;    -   locating the modules adjacent one another and positioning the        conditioning elements to permit engagement of said adjacent        modules; and    -   deploying the conditioning elements wherein the modules are        together configured to form a structure.

Preferably the conditioning elements are each in the form of tendons andthe step of deploying the conditioning elements involves stressing ofthe tendons. More preferably this involves pre-stressing or posttensioning of the tendons which effects deployment of the structure.Even more preferably the structure is a roof truss and stressing of thetendons provides erection of the roof truss.

Preferably the method of construction also involves the ability to, ifrequired, reconfigure the structure by placement of packer elementsbetween adjacent of the constructional modules. More preferably thisreconfiguration step is effected prior to deployment of the conditioningelements.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to achieve a better understanding of the nature of the presentinvention a preferred embodiment of a constructional module and acorresponding structure including a plurality of constructional modulestogether with a method of construction will now be described in somedetail, by way of example only, with reference to the accompanyingdrawings in which:

FIG. 1 is a perspective view of a roof structure constructed inaccordance with an embodiment of the invention;

FIGS. 2A to 2F show in front elevation a structure, or in thisembodiment modular frame, including a plurality of constructionalmodules which in the case of FIG. 2B is taken from the roof structure ofFIG. 1 whereas FIGS. 2A, and 2C to 2F depict different sizes of themodular frame;

FIG. 3A illustrates in side elevation and part enlarged sectional viewone of the constructional modules of the preceding figures;

FIGS. 3B shows various cross-sectional views of alternate constructionalmodules;

FIG. 4 shows an elevational view of adjacent constructional modules anddetails pertaining to upper and lower interlocking connection betweenadjacent modules;

FIGS. 5A to 5C schematically illustrate sequential erection of the rooftruss of for example FIG. 2B;

FIG. 6 shows in elevational and enlarged part perspective view claddingof for example the roof structure of FIG. 1; and

FIG. 7 shows in perspective and sectional views an end wall of theredeployable roof structure of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As best shown in FIG. 1 there is a building or shelter system 10comprising a series of structures or in this embodiment modular frames12A to 12F being arranged generally parallel to and laterally spacedfrom one another, and interconnected with in this example, roof sheetingdesignated generally as 14. The modular frames such as 12A are each intheir erected condition in the form of a roof truss each including aplurality of constructional modules or in this example truss modules orpanels such as 16A and 16B.

As shown in FIG. 3A each of the truss panels such as 16A is shaped inthe form of a trapezium including upper and lower substantially parallelchord members 18 and 20, respectively, which are interconnected atopposite ends with web members 22 and 24. The truss panel 16A alsoincludes a diagonally oriented web member 26 which provides additionalrigidity to the truss panel 16A. Alternatively the diagonal web member26 is one of a pair of diagonal web members which together form an “X”.Each of the truss panels such as 16A of this embodiment are of asubstantially identical profile shape and constructed of a compositematerial with the chord and web members being of a hollow section. Forexample, the lower chord 20 of the truss panel 16A as shown in thedetailed sectional view of FIG. 3 is formed as a square hollow section(SHS) having an internal void 28. FIG. 3B illustrates three (3)alternate constructional modules or panels each having solid webs ratherthan the diagonal web member 26 of the previous embodiment. In order toavoid repetition, and for ease of reference, like components of thisembodiment have been designated with an additional “0”, for example thetruss panel 160.

The composite material from which the constructional modules of thisembodiment are formed is a particulate filled resin (PFR) material whichpermits the truss panels to be cast or moulded. This provides alightweight and robust material which is relatively easy to manufactureand the PFR has a reduced amount of expensive high strength fibres suchas kevlar and carbon fibre but rather relies upon a low cost filler toprovide robustness, placement and protection to the fibres somewhatanalogous to reinforced concrete where the higher strength steelreinforcement is positioned and protected by the concrete filler.

An alternate technique is for the truss panels such as 16A or otherconstructional modules to be “pultruded” from a composite material. Inthis alternate example the module is fabricated from separate sections,each pultruded from a composite material and fixed together.

As shown in FIGS. 2A to 2F the truss panels such as 16A and 16B of thisembodiment are of the predetermined trapezium configuration so that onengagement, or in this case abutment, with one another they togetherform the building structure or module frame such as 12A. In the examplesof FIGS. 2A to 2F the modular frame such as 12A is configurabledepending on the number and relative positions of the truss panels suchas 16A and 16B or other constructional modules. In this embodiment thestructure or modular frame such as 12A includes packer elements (notillustrated) located between adjacent truss panels such as 16A and 16Bto adapt the modular frame such as 12A for different span, height andpitched roof structures 10. The packer elements are designed to locatein the space between adjacent lower chord members such as 20 of adjacenttruss panels such as 16A and 16B to adjust the spacing between modulesor panels 16A/B and hence the geometry of the modular frame 12A.

The structure or modular frame 12A of this example also includesconditioning elements arranged to cooperate with the constructionalmodules or truss panels such as 16A and 16B to form the modular frame12A. In this case the conditioning elements include tendons which locatewithin the hollow section of the upper and/or lower chord member 18 or20 of adjacent and abutting truss panels such as 16A and 16B. This isbest illustrated in FIG. 4 where the conditioning element or lowertendon 28 passes through adjacent lower chord members 20A and 20B ofadjacent and abutting truss panels 16A to 16C. As will later bedescribed in more detail, the conditioning means or lower tendon 28 isdeployed or in this example stressed or tensioned to facilitatecooperative movement of the truss panels such as 16A and 16B and as sucherection of the modular frame 12A.

The adjacent constructional modules or truss panels 16A and 16B eachinclude interlocking means arranged to provide interlocking of thepanels 16A and 16B when in this example they are in abutting engagement.The interlocking means in this construction of the constructionalmodules includes a protrusion or integral spigot such as 30A and 30Blocated at adjacent ends of the upper and lower chord members 18 and 20,respectively.

An opposite end of each of the upper and lower chord members 18 and 20includes a respective hole 32A and 32B which interlocks with the spigotsof the adjacent constructional module or truss panel (see FIGS. 3A and4). This spigot/hole connection permits pivotal movement betweenadjacent of the modules or truss panels such as 16A and 16B which onerection of the modular frame 12A provides a hinged action at thisconnection or abutment of the upper chord members such as 18. Theconstructional module or truss panels are preferentially reinforcedabout the surrounding portion of the spigot and recess such as 30A and32A. Alternately, the connection between the modules or truss panels attop chord level is provided by a pivotal or hinged connector. Thisconnector (not shown) may be in the form of a clevis/pin typearrangement.

As best shown in FIG. 6 the roof structure 10 is clad with elongate andtransversely oriented sheeting being of a trough or channelconfiguration such as 34A to 34F. The roof cladding of this embodimentis fabricated from a rigid plastic material such as PVC or ABS. The roofcladding 34A is substantially half the width of the top chord membersuch as 18 and of a sufficient length to extend between adjacent modularframes such as 12A and 12B with a butted or lapped connection betweenthe cladding. Adjacent of the roof cladding panels such as 34A and 34Bare connected to one another so as to provide a connection which permitshinging action during erection of the modular frame such as 12A. Theroof structure 10 may also be lined with a flexible membrane 36 such asa canvas membrane which seals the cladding 34A to 34C from water anddust. The roof structure 10 may also include an insulation or ballisticsboard 38 which underlies the flexible membrane 36 and sits across theroof cladding such as 34B. In an alternate construction the roofcladding may include a flexible membrane alone such as a fabric coveringfor example canvas.

As shown in FIG. 7 there is an end wall designated generally as 40formed in this example from wall panels of an identical construction tothe roof cladding panels such as 34A. The wall panels such as 42A and42B are, in a similar fashion to the roof cladding panels, of a standardlength, such as 6 metres. The wall panels span vertically from groundlevel to the roof line, and the roof cladding panel overhang togetherwith purpose shaped infills provide some measure of closure to thebuilding. At ground the wall panels may be set in a trench andbackfilled to provide support, and the depth of embedment allows foreffective adjustment of length of the wall panels. Walls panels may alsobe lapped if the standard length is insufficient to vertically span fromground to the roof line. A door opening such as 44 can be supported viaa bolted lintel 46.

The roof structure 10 is particularly well suited to applications whereit can be redeployed. These applications include but are not limited todeployable hangars for the various military forces and ideally aresuited to roof structures having spans of up to around 35 metres butmore often around 15 metres. Redeployable and modular roof structuressuch as those described in the preceding paragraphs are well suited tothese applications where deployment considerations are transportation,relatively fast set up and disassembly. The general steps involved inconstructing the roof structure 10 of the preceding example are asfollows:

-   -   1. as best shown in FIG. 5A, the constructional modules or truss        elements such as 12A are located alongside one another in a        collapsed or flat condition together with the conditioning means        or lower tendon 28 threaded through lower chord members such as        20A and 20B;    -   2. as further shown in FIG. 5A, the roof structure 10 includes        an adjustable support module such as 48A and 50A located at        respective opposing ends of the modular frame 12A with one of        the support panels such as 48A being anchored;    -   3. as best shown in FIG. 5B, the conditioning means or tendon 28        is deployed or tensioned wherein the constructional modules or        in this example trapezium-shaped truss panels are hinged        relative to one another whereupon the modular frame 12A is        progressively raised whilst the other adjustable support panel        50A slides inwardly toward the anchored support panel 48A; and    -   4. as best shown in FIG. 5C, the modular frame or truss        structure 12A is progressively moving to its erected condition        with the adjacent constructional modules or truss panels such as        16A and 16B of this example abutting one another whereupon the        floating support panel 50A is anchored.

This mode of construction enables the modular frame to move from itscollapsed condition to its erected condition largely as a function ofthe geometry of the constructional modules and their mode of connectionin conjunction with the conditioning means or in this example thetendons such as 28. The trapezium-shaped truss panels such as 16A and16B have a shorter lower chord member 20 than the upper chord member 18,and the outer web members 22 and 24 taper toward one another so thateach constructional module or truss panel such as 18A has mutuallyinclined outer side bearing surfaces. It will be appreciated that therespective outer bearing surfaces of the truss panels such as 16A and16B in the collapsed condition are spaced apart except at their upperportion whereas on erection of the modular frame such as 12A the bearingsurfaces are substantially in abutment with one another. However, aswill be appreciated from FIGS. 2A to 2F the spacer elements may beutilised to vary this degree of abutment and thus the configuration ofthe structure or modular frame such as 12A.

Without wanting to be limited by shapes and/or dimension, the followingtable provides sizes for the roof trusses of FIGS. 2A to 2F. Thethickness of the spacer elements or packers located between adjacentmodules or truss panels such as 16A and 16B are also given. ModularWidth Height Packer thickness No. of truss Frame (m) (m) (mm) panels35.23 11.112 No packer 32 19.669 8.5 No packer 20 35.189 12.5 80 3253.05 15.0 120 44 30.714 9.0 80 26 38.643 10.0 100 30

Now that a preferred embodiment of the present invention has beendescribed in some detail, it will be apparent to those skilled in theart that at least the preferred embodiment of the constructionalmodule/structure and method of construction have at least the followingadvantages:

-   -   1. The constructional modules are relatively compact and        lightweight and as such lend themselves to redeployable        structures;    -   2. The structure being of a modular design can be erected with        relative ease requiring minimal tools and trade skills;    -   3. The structure is reconfigurable by varying the relative        positions of the constructional modules, using a different        number of modules, and/or varying the deployment of the        conditioning elements;    -   4. The structure can be adapted for differing conditions and for        example include additional conditioning elements in the form of        tendons arranged along the upper chord of for example the truss        frame;    -   5. The structure can be assembled at ground level and then        erected using the conditioning elements which for example are        tensioned, and as such this method of deployment minimises        safety requirements for working at heights;    -   6. The structure and associated building system provides a        relatively large clear span roofing system;    -   7. The structure and constructional modules have a minimum        number of loose components but rather include “captive”        components which avoid loss in adverse conditions;    -   8. The constructional modules of the structure permit compact        storage and transportation, for example the modules may be fully        containerised in standard freight containers transported by air,        road, rail or sea; and    -   9. The structure is formed largely from components which are        identical and as such there are a minimum number of components        to handle and inventorize, and it is easier and more manageable        to have spares.

Those skilled in the art will appreciate that the invention describedherein is susceptible to variations and modifications other than thosespecifically described. For example, the constructional modules may beshaped differently to the trapezium-shaped truss panels of the describedembodiment. The panels need not be limited to a composite constructionbut for example they extend to other preferably lightweight materialssuch as aluminium alloy, or alternatively steel. Similarly, the roofcladding may be constructed of any suitable material although highpressure thermoformed (HPT) plastics such as PVC are preferred. Thebuilding structure may in military applications include passive oractive means to reduce the radar signature of the redeployable structureand any contained equipment. Ideally, the shelter system materials willprovide a minimised radar signature and it is expected that specialcoverings may be able to actively shield the internal equipment.Otherwise, it is preferable that the structure or in the describedembodiment redeployable building system includes environmentalconditioning systems (heating/cooling) and ventilation, is capable ofchemical agent decontamination using standard procedures when erected,can provide blackout capability, and/or provides camouflage capability.The structure need not be limited to the roof truss described but mayfor example extend to bridges and other structures.

All such variations and modifications are to be considered within thescope of the present invention, the nature of which is to be determinedfrom the foregoing description.

1. A structure comprising: a plurality of constructional modules beingof a predetermined configuration; one or more conditioning elementsbeing arranged to cooperate with the constructional modules whereinadjacent of said modules engage one another to form the structure; andone or more packer elements being adapted to locate between adjacent ofthe constructional modules to effect reconfiguration of the structure.2. A structure as defined in claim 1 wherein the conditioning elementsinclude an upper tendon and a lower tendon being arranged to cooperatewith an upper chord member and a lower chord member, respectively, ofeach of the constructional modules.
 3. A structure as defined in claim 2wherein the respective tendons are designed to locate within a hollowsection of the lower and upper chord members and stressing of thetendons involves pre-stressing or post tensioning of the tendons and thecorresponding chord member.
 4. A structure as defined in claim 2 whereinthe constructional module is shaped in the form of a trapezium includingthe upper and lower chord members being substantially parallel andinterconnected at opposite ends with respective web members.
 5. Astructure as defined in claim 4 wherein each of the constructionalmodules is of a substantially identical shape.
 6. A structure as definedin either of claims 4 or 5 wherein the chord and web members are formedas hollow section members.
 7. A structure as defined in claim 6 whereinthe hollow section members are square hollow section (SHS) members.
 8. Astructure as defined in claim 4 wherein the trapezium-shapedconstructional module includes a pair of diagonal web members arrangedto add rigidity to the module.
 9. A structure as defined in claim 1wherein the constructional module includes interlocking means beingarranged to provide interlocking of the adjacent modules.
 10. Astructure as defined in claim 9 wherein the interlocking means includesan integral spigot being adapted to engage a hole of an adjacent module,or vice versa, and designed to permit pivotal movement between adjacentof said modules.
 11. A structure as defined in claim 10 wherein thespigot or hole allows a hinged action between said adjacent modules. 12.A constructional module or a structure as defined in either of claims 10or 11 wherein the spigot and/or hole together with the surroundingportion of the constructional module is reinforced.
 13. A structure asdefined in claim 1 wherein the constructional modules are of a compositeconstruction.
 14. A structure as defined in claim 13 wherein thecomposite constructional modules are fabricated from a fibre compositematerial.
 15. A structure as defined in claim 14 wherein the fibrecomposite material is a particulate filled resin material with highstrengths fibre reinforcement, or a polyester resin based material. 16.A constructional module or a structure as defined in claim 1 wherein theconstructional module is formed from a polymeric material.
 17. Aconstructional module or a structure as defined in claim 16 wherein thepolymeric material is pultruded.
 18. A structure as defined in claim 1wherein each of the constructional modules is a truss module.
 19. Astructure as defined in claim 1 wherein the structure is a buildingstructure.
 20. A structure as defined in claim 19 wherein the buildingstructure is a roof truss clad with elongate and transversely orientedsheeting.
 21. A structure as defined in claim 20 wherein the sheeting isof a channel section and fabricated of a rigid material.
 22. A structureas defined in claim 20 wherein the cladding is made from a fabric.
 23. Astructure as defined in claim 1 wherein the structure is redeployable.24. A method of construction, said method including the steps of:providing a plurality of constructional modules each being of apredetermined configuration, one or more conditioning elements beingarranged to cooperate with said modules, and one or more packer elementsbeing adapted to locate between adjacent of the constructional modules;locating the modules adjacent one another and positioning theconditioning elements to permit engagement of said adjacent modules;deploying the conditioning elements wherein the modules are togetherconfigured to form a structure, the packer elements being arranged toeffect reconfiguration of the structure.
 25. A method as defined inclaim 24 wherein the reconfiguration step is effected prior todeployment of the conditioning elements.
 26. A method as defined ineither of claims 24 or 25 wherein the conditioning elements are each inthe form of tendons and the step of deploying the conditioning elementsinvolves stressing of the tendons.
 27. A method as defined in claim 26wherein stressing of the tendons involves pre-stressing or posttensioning of the tendons which effects deployment of the structure. 28.A method as defined in claim 26 wherein the structure is a roof trussand stressing of the tendons provides erection of the roof truss.
 29. Amethod as defined in claim 27 wherein the structure is a roof truss andstressing of the tendons provides erection of the roof truss.